Mimicking the Gecko

Nearly five years ago, Breakout Labs funded Pittsburgh-based startup nanoGriptech because of its unique approach to advancing adhesives. Inspired by the gecko’s ability to scuttle up walls and across ceilings due to their millions of micro/nano foot-hairs, nanoGriptech develops a new kind of microfiber adhesive material that is strong, lightweight, and reusable without requiring glues or producing harmful residues. With Breakout Labs funding, the company was able to work through critical manufacturing steps to increase production while reducing costs.

We sat down with CEO Nicholas Kuhn to learn more about this sticky startup.

Breakout Labs (BOL): Nicholas — thanks for carving out some time today to chat about nanoGriptech. First, tell us more about how your unique gripping technology works.

Nicholas: Our technology’s genesis is the Gecko’s foot and more specifically their toe pads. Gecko’s have millions of foot-hairs called setae. That’s where we came up with our brand name — Setex. We create mushroom shaped fibers, biomimicking the gecko setae, using a range of different technologies. If we injection mold the shape, we can make materials that have super skin-gripping characteristics in wet and oily environments. If we coat them onto a backing, we can make dry adhesive tape. If we attach a second mating surface, we can make a super thin, light-weight closing device like Velcro but quieter, more flexible and lighter weight.

We have approximately 75 different microstructures that all have different performance characteristics. For example, our product, the GeckoGrip, is great for any application that requires soft gripping of the skin. Other products include the GeckoTape, which is a dry adherent for smooth surfaces and the Ultra-Thin Fasteners, which provide a hermetic seal.

BOL: Wow, that covers quite a broad range of uses. Can you tell us more about specific applications?

Nicholas: Sure. We have three Setex products: the GeckoGrips, the GeckoTape, and the Ultra-Thin Fasteners.

The GeckoGrips can literally be used in any application that needs soft grip to skin. So the sky is the limit! Think eyewear, earbuds, fitness bands, racquets, bats, golf grips, bike grips, and the list goes on! There are also a range of medical applications like orthotics, braces, prosthetics, face masks. The broad categories are wearables, sports and medical.

And although our primary customers are other businesses, this year, we launched our Setex GeckoGrip nose pads for eyewear. We have sold over 10,000 5-packs since launch in January on Amazon. Users love them for keeping their glasses secure while working out, or just for general comfort. We have had some amazing reviews on Amazon.

Our vision is to build the Setex brand and build awareness of our technology, and use that to drive OEM relationships also.

BOL: What about the GeckoTape? Why do people need a dry adhesive instead of just using some sort of glue?

Nicholas: The GeckoTape is our dry adhesive tape that feels dry, and adheres to smooth surfaces with a mechanical bond rather than a chemical bond. This means it can provide repeatable adhesion — we had one customer test it 250,000 times. Performance drops only slightly over time. It leaves almost no residue. While applications are limitless, using the technology in high-margin, expensive manufacturing processes is our sweet spot. We have seen the most traction in semiconductor manufacturing, which is a specific focus for us. Because the bond is mechanical, the technology holds the promise of creating a tape that can function in extremely high temperature environments.

BOL: And the ultra-thin fasteners? How good a seal can you create with them?

Nicholas: Well, customers have used the Ultra-Thin Fasteners in closure applications that need a hermetic seal such as biochemical hazard suits and tents, so I’d say that’s a pretty good seal indeed! A high pressure resistant, flexible, hermetic closure system is required to protect against hazardous gas exposure. So, such seals are required on collective protection systems, inflatable shelters, vestibule attachments, body bags, chemical/biological protective apparel, or systems for transportation of sick individuals. Conventional fastening options for such applications generally consist of zippers, hook and loop closures, or zip-track systems, which can allow permeation of chemical and biological contaminants.

But, we’re not just talking about safety with these fasteners. Another application is automotive seating. Because upholstery can not be permanently adhered to the seat structure for various maintenance-related reasons, the snugness of leather upholstery tends to loosen around the seat cushion, causing permanent pockets of loose leather. The Ultra-Thin Fastener is a solution that can reduce damage to the car seat from “aging,” lowering costs of recalls and reputational damage, while allowing for innovations in seating design and ergonomics.

BOL: It sounds like you have no shortage in the types of customers you can engage. Are there particular new areas you are excited about?

Nicholas: On the consumer side, we are moving into consumer electronics and gaming. On the commercial side, we want to penetrate the many layers of semiconductor manufacturing, as well as expand our automotive clients. As we drive the cost of our technology down, we expect to move into more value-based applications like packaging.

BOL: I understand nanoGriptech is a Carnegie Mellon spin out. Tell us why you decided to stay local to the area.

Nicholas: Yes, we are a Carnegie Mellon spin out, and even though we are over 10 years old, we still feel rooted in CMU and Pittsburgh. Many of our engineers went to CMU and Pitt, and our offices are in Lawrenceville, which is a hip part of the city. In the tradition of this old steel town, we manufacture our products in Pittsburgh, and are proud of our Made in the USA label.

BOL: Back in March, you closed a $6M Series A — congrats! What milestones do you hope to achieve with this funding?

Nicholas: We plan on launching a half dozen consumer products within the next six months. We will be scaling our manufacturing operations, and building out our quality system. In addition, we expect to complete the pilot work on a roll-to-roll manufacturing system that is important in taking a major technology step forward for the company.